Terminal sensor

ABSTRACT

An automatic system for severing a length of wire from a supply, stripping insulation from one end, applying a metal terminal to the stripped wire end, attaching a terminal to the end of the wire by crimping in a press, advancing the end of the wire with the terminal attached to a sensor, determining whether or not a terminal has been applied to the wire, and terminating automatic operation of the system if the sensor determines that the wire does not have a terminal attached.

[4 1 Mar. 12, 1974 States ae [1 1 l 1; HQ aldyga 2/1969 Keller 29/203 DTERMINAL SENSOR [75] Inventor: Joseph W. Baldyga, Mt. Clemens,

Mich.

Primary ExaminerThomas H. Eager Attorney, Agent, or Firm-Whittemore,Hulbert & Belknap M a C M O M we mM 05 mm .mk DC n c t Appl. No.:271,836

[57] ABSTRACT An automatic system for severing a length of wire 22Filed:

from a supply, stripping insulation from one end. ap-

u.s. Int Cl 29/203 D H0lr 43/04 Field of Search minal attached to asensor, determining whether or not a terminal has been applied to thewire, and termi- S A m2 THP o 3 m m, mD3 Noam "0/ mm 9 m2 a. 5 rtReferences Cited nating automatic operation of the system if the sensorUNITED STATES PATENTS determines that the wire does not have a terminalattached.

Andren 29/203 D 29/203 D 9 Claims, 7 Drawing Figures PATENTED HAR I 2I974 SHEET 1 OF 2 SHEET 2 BF 2 PMENTEDMARI 2mm FIGB TERMINAL SENSORBRIEF SUMMARY OF THE INVENTION The present invention relates to thecombination of automatic mechanism for preparing wire sections for theapplication of terminals and the automatic attachment of terminals to abared wire end by means of a crimping press, and means for sensing eachcompleted wirre section supplied with a terminal to determine if aterminal has been properly applied. If no terminal has been applied thesensor terminates automatic operation of the mechanism. Moreparticularly, the mechanism draws a length of wire from a reel, cuts itto the proper length, strips insulation from the forward end of thewire, advances the bared end of the wire into an open terminal, andadvances the wire and loosely applied terminal to a crimping press whichoperates to crimp the terminal permanently in place on the bared end ofthe wire. So long as the operation is being performed satisfactorily, itcontinues in a fully automatic manner, terminals being supplied to thepress by suitable terminal advancing means in which the terminals may beseparately applied to a tape or the like.

Immediately adjacent the press, in accordance with the presentinvention, there is applied a terminal sensor. The operation of themechanism is intermittent and after a terminal has been applied to awire in the press, the completed unit is advanced one step in which itmay be received in the sensor. Alternatively, the sensor may be spacedsomewhat further from the press so that a small number of units may bepositioned intermediate the press and the sensor.

In general terms, the sensor comprises an anvil and a head movablethrough the medium of a relatively light spring actuated by a solenoid.Ifa satisfactorily applied terminal is on the anvil, movement of thehead is arrested, the solenoid is de-energized, and the operationcontinues in a fully automatic manner. If however, a satisfactorilycompleted terminal is not present in the sensor upon any singleoperation thereof, the head continues downwardly and actuates amicro-switch which is effective to terminate automatic cycling of themechanism.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a diagrammatic view of thecomplete apparatus.

FIG. 2 is an enlarged perspective view of the terminal sensor.

FIG. 3 is a side elevation of the terminal sensor.

FIG. 4 is a front elevation of the terminal sensor.

FIG. 5 is a fragmentary sectional view on the line 5-5, FIG. 3.

FIG. 6 is a fragmentary sectional view on the line 66, FIG. 3.

FIG. 7 is a diagrammatic showing of the control circuit for the system.

DETAILED DESCRIPTION Referring first to FIG. 1 the entire system isillustrated more or less diagrammatically in perspective. A supply ofinsulated wire W is provided on a reel 10 which is shown as supported ona bracket 12. The system includes a frame 14 made up of an end plate 16and a top plate 18 carrying at its underside mechanism diagrammaticallyindicated at 20 which withdraws a measured length of wire from the reel10, strips insulation from at least its forward end, advances the baredend of the wire into an open terminal T preferably carried by a tape 22which is intermittently advanced by the machine, and deposits the lengthof wire in an open topped tray indicated at 24.

The press is diagrammatically indicated at P and includes a verticallymovable ram 26 normally spaced from a base 28.

During automatic cycling of the machine the wire carrying an openterminal into which the bared end of the wire W has been inserted, isintermittently advanced to position the open terminal between the base28 and the ram 26 of the press P. This may conveniently be accomplishedby an endless conveyor comprising belts 30 carrying a sequence ofsupports 32, the supports including upwardly extending arms adapted toengage severed portions of the wire W to lift them from the open tray 24and convey them into operative relation to the press P. In some casesthe severed length of wire may be moved into registration with the openterminal and moved into the terminal while the terminal is in positionbeneath the ram 26 of the press. At this time the press is actuated, theram moves downwardly to crimp the terminal permanently onto the baredend of the wire and returns upwardly. Upward movement of the ram 26 maybe arranged to time advance of the tape and to initiate operation of thewire withdrawing, severing, and stripping mechanism diagrammaticallyindicated at 20.

The foregoing apparatus is of known construction and has not been shownin detail.

The present invention comprises the addition of a sensor 40 which ispositioned as close as practical to the press P so as to reduce to aminimum wires advanced by the conveyor belts 30 and located intermediatethe press P and the sensor 40.

Referring now more particularly to FIGS. 26, the sensor comprises astand 42 including a base 44 on which is mounted a housing 46 containinga solenoid, and forwardly extending arm 48. The forward end of the arm48 is provided with an anvil surface 50 and inclined guide surfaces 52.

Carried by the sensor 40 is a sensing bar or head 54 mounted forvertical movement by means of guide pins 56 movable in guide openings 58provided in sleeves 60 carried in openings in the arm 48. The sensingbar or head 54 includes a sensing surface 62 and inclined surfaces 64which cooperate with surfaces 52 to provide tapering entrance and exitpaths for the end of the conductor provided with the crimped terminals.

As best seen in FIG. 6, compression springs 66 are provided in recesses68 and 70 formed in the confronting surfaces of the head 54 and arm 48respectively. These springs are selected to provide sufficient force tobias the head 54 upwardly but to permit downward movement thereof aswill subsequently be described.

Upward movement of the head 54 is limited by stop nuts 72 carried by astud 74 projecting upwardly from the arm 48. The head 54 also carries anadjustable switch actuating stud 76 threaded into an opening in the head54 and locked in place by a lock nut 78. The lower end of the stud 76 ismovable in an opening 80 which extends through the arm 48.

The housing 46 contains a solenoid including a plunger connected to anupwardly extending connec- I tion 82 including a pin 84 by means ofwhich a light tension spring 86 is connected to a pin 88 carried by thehead 54.

Directly beneath the arm 48,there is provided a mi-. cro-switch 90having an upwardly extending actuating button 92 adapted to be engagedby the lower end of the actuating stud 76 upon predetermined downwardmovement of the head.

In general terms a control system for the complete apparatus is providedwhich is effective to cause continuous repeated cycles of the machine solong as a supply of wire W remains on the reel and so long as terminalsT are supplied to the press P. Each time the press head moves downwardlya circuit is completed energizing the solenoid within the housing 46 andurging the movable sensor head 54 downwardly. This is timed to occur atan interval during which the conveyor is at rest and while, if theapparatus is operating satisfactorily, a completed assembly of terminaland wire end is located in the space between the anvil surface and thesurface 62 of the sensor head. Downward movement of the head 54 inresponse to energization of the solenoid is arrested before the lowersurface of the stud 76 engages the button 92 of the microswitch 90. Ifhowever, a properly finished terminal end of wire is not present in thesensor, the head 54 is permitted to move further downwardly so that themicroswitch 90 is actuated by the stud 76. This is effective to shutdown operation of the entire apparatus until the supply of wire orterminals is renewed or until whatever difficulty caused the lack of aproperly finished terminal in the sensor is corrected.

In FIG. 2 there is shown a switch 94 having an actuating arm 96 adaptedto be engaged by a part of the appa-" ratus movable downwardly with theram 26 of the press. Thus, the switch 94 will be closed for a briefinterval coinciding with the lowermost position of the press, at whichtime the conveyor 30 is of course stationary. The switch actuating stud76 may be very accurately adjusted so that actuation of the micro-switch90 will be prevented only ifa complete crimped terminal is provided on awire end. If no terminal were applied to the stripped end of the wire,as would be the case if the supply of terminals were exhausted, thebared wire end will not prevent actuation of the microswitch 90. On theother hand, if the supply of wire on the reel 10 were exhausted, it willbe appreciated that subsequent advance of the conveyor 30 would notadvance a wire section to the sensor. Thus, if either the supply of wireor terminals is exhausted, the system will automatically shut down.

The control circuit for carrying out the desired operation is shown inFIG. 7 in which the winding of the solenoid contained in housing 46 isseen at 100, in series with a manually on-off switch 102, controllingopera tion of the solenoid. Also in series with manual switch 102 is thesolenoid activation switch 94 which times operation of the solenoid withcycling of the entire system. Thus, whenever the ram 26 descends,solenoid l00 is energized to activate the sensor 40.

Operation of the entire system, including the wire cutter and stripper,the means for inserting the wire end into an open terminal, and timedactuation of the press P and ocnveyor 30, is controlled by a manualstart-stop switch 104, the system being diagrammatically represented inits entirety at 106. Switch 104 energizes relay R1, in series withnormally open contacts. Rla and normally closed switch 90. Energizationof relay R1 closes contacts Rla in the holding by-pass, and closescontacts Rlb, starting operation of the system.

When the sensor is activated by closure of switch 102, and operation ofthe entire apparatus initiated by momentary closure of start-st p-switch104, the intermittent press operation energizes solenoid 100 at eachcycle, and so long as properly finished terminals are sensed at thesensor 40, the operation continues in a fully automatic manner. When thesensor senses as improperly finished piece, or the absence of a piece,the micro-switch opens momentarily, opening the holding circuit relayR1, and terminating operation of the system.

I claim:

1. Apparatus comprising a system for continuous, automatic production ofinsulated wire elements having terminals crimped to bared conductors atone end thereof comprising an intermittently operated crimping press,means for intermittently advancing a length of insulated wire having itsconductor bared at one end and having a terminal loosely applied theretointo the press, and for advancing a finished piece away from the pressbetween press operations, the combination therewith of a sensor adjacentthe press to receive the end portion of a wire element with a terminalcrimped thereto, said sensor comprising means to determine whether apreceding press operation has produced a crimped terminal on a wire end,and means responsive to said sensor to shut down operation of the systemin the absence at the sensor ofa crimped terminal thereat.

2. Apparatus as defined in claim 1 in which the sensor comprises ananvil, a sensing head movable toward and away form the anvil, and aswitch operable to terminate system operation actuated by predeterminedapproach to the anvil of the head.

3. Apparatus as defined in claim 2 comprising a solenoid, resilientmeans connecting the solenoid to said head to provide a non-positiveforce effective to move said head toward said anvil until its movementis arrested by engagement with the terminal wire end on said anvil.

4. Apparatus as defined in claim 3 in which said solenoid is energizedthrough a switch closed intermittently by movement of a part of saidsystem.

5. Apparatus as defined in claim 3 in which said sensor includes switchmeans including normally closed contacts in a holding circuit includinga relay which when energized continues operation of the system.

6. Apparatus as defined in claim 2 in which said anvil and sensing headhave inclined surfaces defining a tapered guide-way, and parallelsensing surfaces between which the terminal wire end is positioned aftermovement through 'said guide-way.

7. Apparatus as defined in claim 3 comprising spring means effective tomove said head away from said anvil, and in which the resilient meansconnecting the head to the solenoid is effective to overcome said springmeans to produce a resultant force urging said head toward said anvil.

8. Terminal applying apparatus comprising a press for crimping terminalsto wire ends, a sensor, means for advancing a crimped terminal from saidpress to said sensor, said sensor comprising means engageable with aterminal operable to prevent further operation of said press in absenceat said sensor of a properly applied terminal.

9. Apparatus as defined in claim 8 in which said sensor comprises a pairof relatively movable elements engageable with a terminal, and meansoperated in timed relation to operation of said press to effect relativemovement of said elements to engage opposite sides of a terminal at eachoperation of said press.

1. Apparatus comprising a system for continuous, automatic production ofinsulated wire elements having terminals crimped to bared conductors atone end thereof comprising an intermittently operated crimping press,means for intermittently advancing a length of insulated wire having itsconductor bared at one end and having a terminal loosely applied theretointo the press, and for advancing a finished piece away from the pressbetween press operations, The combination therewith of a sensor adjacentthe press to receive the end portion of a wire element with a terminalcrimped thereto, said sensor comprising means to determine whether apreceding press operation has produced a crimped terminal on a wire end,and means responsive to said sensor to shut down operation of the systemin the absence at the sensor of a crimped terminal thereat.
 2. Apparatusas defined in claim 1 in which the sensor comprises an anvil, a sensinghead movable toward and away form the anvil, and a switch operable toterminate system operation actuated by predetermined approach to theanvil of the head.
 3. Apparatus as defined in claim 2 comprising asolenoid, resilient means connecting the solenoid to said head toprovide a non-positive force effective to move said head toward saidanvil until its movement is arrested by engagement with the terminalwire end on said anvil.
 4. Apparatus as defined in claim 3 in which saidsolenoid is energized through a switch closed intermittently by movementof a part of said system.
 5. Apparatus as defined in claim 3 in whichsaid sensor includes switch means including normally closed contacts ina holding circuit including a relay which when energized continuesoperation of the system.
 6. Apparatus as defined in claim 2 in whichsaid anvil and sensing head have inclined surfaces defining a taperedguide-way, and parallel sensing surfaces between which the terminal wireend is positioned after movement through said guide-way.
 7. Apparatus asdefined in claim 3 comprising spring means effective to move said headaway from said anvil, and in which the resilient means connecting thehead to the solenoid is effective to overcome said spring means toproduce a resultant force urging said head toward said anvil. 8.Terminal applying apparatus comprising a press for crimping terminals towire ends, a sensor, means for advancing a crimped terminal from saidpress to said sensor, said sensor comprising means engageable with aterminal operable to prevent further operation of said press in absenceat said sensor of a properly applied terminal.
 9. Apparatus as definedin claim 8 in which said sensor comprises a pair of relatively movableelements engageable with a terminal, and means operated in timedrelation to operation of said press to effect relative movement of saidelements to engage opposite sides of a terminal at each operation ofsaid press.